Adhesive film, adhesive layer-equipped transparent plate and display device

ABSTRACT

To provide an adhesive film by which air bubbles formed at a bonding interface when the adhesive film is used for bonding, readily disappear under normal temperature and normal pressure. 
     One embodiment of the adhesive film of the present invention is characterized by having at least one adhesive layer, wherein the adhesive layer satisfies the following requirements (a) to (c).
         (a) A diffusion coefficient of nitrogen gas is at least 1.5×10 −6  cm 2 /sec,   (b) A shear modulus G′ (1 Hz) is from 5×10 2  to 1.0×10 5  Pa, at a measurement temperature of 25° C. and a frequency of 1 Hz, and   (C) The adhesive layer has an absorption peak at from 800 to 820 cm −1  and no absorption peak at from 1,000 to 1,020 cm −1 , in an infrared absorption spectrum.

CROSS REFRENCE TO RELATED APPLICATIONS

This application, is a continuation application of U.S. application Ser.No. 15/653,572, filed on Jul. 19, 2017, which is a continuation ofInternational Application PCT/JP2016/053566, filed on Feb. 5, 2016, andclaims priority from Japanese Patent Application No. 2015-033448, filedon Feb. 24, 2015, the entire contents of which are incorporated hereinby reference.

TECHNICAL FIELD

The present invention relates to an adhesive film, an adhesivelayer-equipped transparent plate and a display device.

BACKGROUND ART

A display device having a display panel and a protective plate bondedvia an adhesive film, has been known (Patent Document 1).

PRIOR ART DOCUMENTS Patent Documents

Patent Document 1: JP-A-2009-263502

DISCLOSURE OF INVENTION Technical Problem

In a case where a display panel and a protective film are bonded by aconventional adhesive film. air bubbles tend to be formed at theinterface between the adhesive film and the protective film or thedisplay panel, whereby the display image quality of the display paneltends to be impaired. Heretofore, in order to let the air bubblesdisappear, a display device having a display panel and a protectiveplate bonded via an adhesive film is left to stand under pressure athigh temperature (hereinafter, referred to as autoclave treatment).

However, the autoclave treatment may prolong a process time or may causeheat damage of a display panel.

The present invention has been made to solve the above problems, and itis an object of the present invention to provide an adhesive film bywhich, even if air bubbles are formed at a bonding interface when theadhesive film is used for bonding, the air bubbles readily disappearunder normal temperature and normal pressure.

Solution to Problem

The adhesive film of the present invention comprises at least oneadhesive layer, wherein the adhesive layer satisfies the followingrequirements (a) to (c):

(a) a diffusion coefficient of nitrogen gas is at least 1.5×10⁻⁶cm²/sec,

(b) a shear modulus G′ (1 Hz) is from 5×10² to 1.0×10⁵ Pa, at ameasurement temperature of 25° C. and a frequency of 1 Hz, and

(c) the adhesive layer has an absorption peak at from 800 to 820 cm⁻¹and no absorption peak at from 1,000 to 1,020 cm⁻¹, in an infraredabsorption spectrum.

The adhesive layer-equipped transparent plate of the present inventioncomprises a transparent plate and at least one adhesive layer on onemain surface of the transparent plate, wherein the adhesive layersatisfies the following requirements (a) to (c):

(a) a diffusion coefficient of nitrogen gas is at least 1.5×10⁻⁶cm²/sec,

(b) a shear modulus G′ (1 Hz) at a measurement temperature of 25° C. anda frequency of 1 Hz, is from 5×10² to 1.0×10⁵ Pa, and

(c) the adhesive layer has an absorption peak at from 800 to 820 cm⁻¹and no absorption peak at from 1,000 to 1,020 cm⁻¹, in an infraredabsorption spectrum.

Further, the display device of the present invention has a transparentplate and a display panel laminated via the adhesive film.

Advantageous Effects of Invention

According to the present invention, it is possible to provide anadhesive film by which, even if air bubbles are formed at a bondinginterface when the adhesive film is used for bonding plates, the airbubbles disappear under normal pressure, and an adhesive layer-equippedtransparent plate. Further, it is possible to provide a display devicein which formation of air bubbles is suppressed.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a plan view illustrating an adhesive film having one adhesivelayer of the present embodiment.

FIG. 2 is a cross-sectional view along in FIG. 1 of the adhesive film ofthe present embodiment.

FIG. 3 is a cross-sectional view illustrating an adhesive film havingtwo adhesive layers of the present embodiment.

FIG. 4 is a view schematically illustrating a production apparatus forproducing an adhesive film having one adhesive layer of the presentembodiment.

FIG. 5 is a view schematically illustrating a production apparatus forproducing an adhesive film having two adhesive layers of the presentembodiment.

FIG. 6 is a cross-sectional view illustrating an adhesive layer-equippedtransparent plate having one adhesive layer of the present embodiment.

FIG. 7 is a cross-sectional view illustrating an adhesive layer-equippedtransparent plate having two adhesive layers of the present embodiment.

FIG. 8 is a cross-sectional view illustrating a display device having anadhesive layer of the present embodiment.

DESCRIPTION OF EMBODIMENTS

Now, embodiments of the present invention will be described withreference to the drawings.

Here, the scope of the present invention is by no means limited to thefollowing embodiments, and may be optionally modified within the rangeof the technical idea of the present invention. Further, in thefollowing drawings, the respective structures may be shown asdifferentiated in their sizes, numbers, etc. from the real structures inorder to make various constructions easily understandable.

In the explanation of the present embodiment, an adhesive layersatisfying the requirements (a) to (c) as explained below will bereferred to as an adhesive layer I, and an adhesive layer other than theadhesive layer I will be referred to as an adhesive layer II. Further,in the case of indicating both of the adhesive layer I and the adhesivelayer such an adhesive layer will be simply referred to as an adhesivelayer.

(Adhesive Film)

The adhesive film of the present embodiment has at least one adhesivelayer I. In view of easiness of handling, an adhesive film has such astructure that an adhesive layer is sandwiched between a pair ofprotective films or a structure that one protective film having anadhesive layer provided thereon is wound into a roll shape, whereby itis possible to cut out and transport an adhesive layer without touchingthe adhesive layer.

[Adhesive Layer I]

The adhesive layer I of the present invention satisfies the followingrequirements (a) to (c), that is the characteristics (a) to (c).

(a) a diffusion coefficient of nitrogen gas is at least 1.5×10⁻⁶cm²/sec,

(b) a shear modulus G′ (1 Hz) is from 5×10² to 1.0×10⁵ Pa at ameasurement temperature of 25° C. and a frequency of 1 Hz, and

(c) the adhesive layer has an absorption peak at from 800 to 820 cm⁻¹and no absorption peak at from 1,000 to 1,020 cm⁻¹, in an infraredabsorption spectrum.

The adhesive layer I has a diffusion coefficient of nitrogen gas beingat least 1.5×10⁻⁶ cm²/sec, and therefore even when air bubbles areformed at the bonding interface, the air bubbles disappear in a shorttime.

When an adhesive film is bonded to an object, air bubbles are likely toform at the bonding interface. The present inventors have found that airbubbles formed at the bonding interface when an adhesive film is bondedto an object, disappear in a short time, in a case where diffusioncoefficient of nitrogen gas among various gases is suppressed within theabove range.

The diffusion coefficient of nitrogen gas in the adhesive layer I ispreferably at least 1.55×10⁻⁶ cm²/sec., particularly preferably at least1.6×10⁻⁶ cm² /sec. in view of excellent disappearance characteristics ofair bubbles. On the other hand, the diffusion coefficient of nitrogengas in the adhesive layer I is preferably at most 3.0×10⁻⁶ cm²/sec. Ifthe diffusion coefficient of nitrogen gas in the adhesive layer Iexceeds 3.0×10⁻⁶ cm²/sec., air bubbles are likely to be formed at thebonding interface between the adhesive layer I and an object to bebonded, and therefore adhesion at the bonding interface tends todeteriorate.

The diffusion coefficient of nitrogen gas in the adhesive layer I iscalculated by means of formula 1 from the thickness of an adhesive layerand a delay time t₀ in a non-steady state measured under the followingconditions 1, by using a high temperature and high pressure gaspermeability measurement apparatus (for example, apparatus name:K-315-H, manufactured by Tsukuba Rika Seiki K.K.).

(Conditions 1)

-   -   An adhesive layer is bonded to one side of a 30 μm-thick        stretched polypropylene substrate to prepare a sample.    -   The sample is sandwiched by a cell, and nitrogen gas is        introduced from the substrate side.    -   A mass of the nitrogen gas permeated via the sample sandwiched        by the cell is analyzed'by a mass spectrometer thereby to        measure the lapse of time of the mass.    -   A high purity product is used as the nitrogen gas, a measurement        temperature is 25° C., a pressure is 100 kPa, and a cell of 50        mm in diameter is used.

Diffusion coefficient D _(N2) of nitrogen gas=L ²/(6×t ₀)   Formula 1:

wherein a delay time t₀ is a value (t₀=t₁−t₂) obtained by subtracting adelay time t₂ in a non-steady state of a permeability curve of only thesubstrate from a delay time t₁ in a non-steady state of a permeabilitycurve of the sample, and L is a film thickness (unit: cm) of theadhesive layer.

In the adhesive layer I, the diffusion coefficient of air is preferablyat least 1.7×10⁻⁶ cm²/sec. When the diffusion coefficient of air is atleast 1.7×10⁻⁶ cm²/sec., the diffusion rate of air in the adhesive layerI would be high. As a result, even if air bubbles are formed at theinterface between an adhesive film and an object to be bonded, the airbubbles would disappear in a shorter time under a normal pressure. Thediffusion coefficient of air is more preferably at least 1.8×10⁻⁶cm²/sec., furthermore preferably at least 2×10⁻⁶ cm²/sec. On the otherhand, the diffusion coefficient of air in the adhesive layer I ispreferably at most 3×10⁻⁶ cm²/sec. If the diffusion coefficient of airin the adhesive layer I exceeds 3×10⁻⁶ cm²/sec., the adhesion of theadhesive layer I at the bonding interface tends to deteriorate.

The diffusion coefficient of air is measured by using the same apparatusas in the measurement of the diffusion coefficient of nitrogen gas,under the same conditions as in the measurement of the diffusioncoefficient of nitrogen gas except that the following conditions 2 areemployed.

(Conditions 2)

Air is used, a measurement temperature is 25° C., a pressure is 100 kPa,and a cell of 50 mm in diameter is used.

In the adhesive layer I, the diffusion coefficient of oxygen gas is morepreferably at least 1.9×10⁻⁶ cm²/sec. When the diffusion coefficient ofoxygen is at least 1.9×10⁻⁶ cm² /sec., most of gas in the air quicklydiffuses in the adhesive layer I, and therefore even if air bubbles areformed at the interface between an adhesive film and an object to bebonded, the air bubbles would disappear in a short time under a normalpressure. The diffusion coefficient of oxygen in the adhesive layer I ismore preferably at least 2×10⁻⁶ cm²/sec., particularly preferably atleast 2.1×10⁻⁶ cm²/sec. On the other hand, the diffusion coefficient ofoxygen gas in the adhesive layer I is preferably at most 3×10⁻⁶ cm²/sec.If the diffusion coefficient of oxygen gas in the adhesive layer Iexceeds 3×10⁻⁶ cm²/sec., the adhesion of the adhesive layer I at thebonding interface tends to deteriorate.

The diffusion coefficient of oxygen gas is measured by using the sameapparatus as in measurement of the diffusion coefficient of nitrogengas, under the same conditions as in the measurement of the diffusioncoefficient of nitrogen gas except that the following conditions 3 areemployed.

(Conditions 3)

A high purity product is used as the oxygen gas, a measurementtemperature is 25° C., a pressure is 100 kPa, and a cell of 50 mm indiameter is used.

A shear modulus G′ (1 Hz) of the adhesive layer I is from 5×10² to 1×10⁵Pa, at a measurement temperature of 25° C. and a frequency of 1 Hz. Theshear modulus G′ (1 Hz) of the adhesive layer I is within such a range,and it is thus possible to maintain the shape of the adhesive layer Iand to fix the object when the adhesive film of the present embodimentis used for bonding. If the shear modulus G′ (1 Hz) is less than 5×10²Pa, the adhesive layer I is likely to be deformed, and therefore evenwhen the adhesive film is used for bonding, the object may not be fixed.On the other hand, if the shear modulus a (1 Hz) of the adhesive layer Iexceeds 1×10⁵ Pa, the adhesive layer I would be too hard, and therefore,for example, in a case where the object to be bonded has irregularitiessuch as steps, the adhesive layer I may fail to follow theirregularities, whereby air bubbles are likely to remain on theirregularities.

The shear modulus G′ (1 Hz) of the adhesive layer I is more preferablyfrom 1×10³ to 8×10⁴ Pa, furthermore preferably from 5×10³ to 5×10⁴ Pa.When the shear modulus G′ (1 Hz) of the adhesive layer I is within theabove range, it is possible to suppress deformation of the adhesivelayer I, and further it is possible to suppress formation of air bubblesat the interface between an object to be bonded and the adhesive layerat the time of bonding.

The adhesive layer I has an absorption peak at from 800 to 820 cm⁻¹ andno absorption peak at from 1,000 to 1,020 cm⁻¹, in an infraredabsorption spectrum. In the infrared absorption spectrum, the absorptionpeak at from 800 to 820 cm⁻¹ is an absorption band of out-of-planebonding vibration of C—H in a vinyl group. Further, the absorption peakat from 1,000 to 1,020 cm⁻¹ is an absorption band (typically, anabsorption peak is present at 1,010 cm⁻¹) of stretching vibration ofSi—O—Si. If the adhesive layer I has a Si—O—Si bond, the adhesive layerI tends to be turbid when contacted with moisture air or water. Forexample, if the adhesive layer becomes turbid at the time of bonding atransparent plate to a display panel, the quality of the display devicewill deteriorate.

Further, the absorption at from 800 to 820 cm⁻¹ and the absorption atfrom 1,000 to 1,020 cm⁻¹ may, for example, be confirmed by infraredabsorption spectrum measurement using a sample having the adhesive layerI bonded to a sample folder.

The glass transition temperature of the adhesive layer I is preferablyat most −65° C. When the glass transition temperature of the adhesivelayer I is within the above range, the adhesion to an object to bebonded would be high at a normal temperature. The glass transitiontemperature of the adhesive layer I is more preferably at most −70° C.

The adhesive layer I is preferably such that tan δ is from 0.01 to 1.4at a measurement temperature of 25° C. and a frequency of 1 Hz. When tanδ is within such a range, it is possible to sufficiently fix objects tobe bonded to each other even when the objects are placedperpendicularly. Further, it is possible to prevent the bondinginterface from slipping with time by e.g. plastic deformation of theadhesive layer I because of the own weights of the objects to be bonded.Tan δ is more preferably from 0.05 to 1, furthermore preferably from 0.1to 0.8.

The thickness of the adhesive layer I is not particularly limited, andmay be freely designed depending on the application of the adhesivefilm. For example, when the adhesive film is used to bond a protectiveplate to a display panel of a display device, the thickness ispreferably from about 0.1 to 2 mm, more preferably from 0.15 to 1.5 mm.When the thickness of the adhesive layer I is at least 0.1 mm, in a casewhere a protective plate and a display panel of a display device arebonded, the adhesive layer will effectively absorb e.g. a shock by anexternal force from the protective plate side, and can thereby protectthe main body of the display device. Further, even if a foreign matternot exceeding the thickness of the adhesive layer is included betweenthe protective plate and the display panel of the display device, thethickness of the adhesive layer will not change substantially, and therewill be little influence over the light transmitting performance. Whenthe thickness of the adhesive layer is at most 2 mm, it becomes easy tobond the protective plate to the display panel of the display device viathe adhesive layer, and the entire thickness of the display device canbe made thin. Here, the above bonding of a protective plate and adisplay panel of a display device, means that the above protective plateand the display surface of the display panel of the display device, thatis an image display surface, are bonded, and the same applies in thepresent specification.

[Resin Composition]

It is preferred that the adhesive layer I is formed by curing a resincomposition as mentioned below. Now, components in the resin compositionwill be described.

The resin composition contains, as an essential component, a curablecomponent I having photocurability. The curable component I contains, asan essential compound, a compound having an absorption peak at from 800to 820 cm⁻¹ corresponding to an absorption band of out-of-plane bondingvibration of C—H in a vinyl group.

It is preferred that the resin composition contains the followingnon-curable component II and a photopolyrnerization initiator III.

(Curable Component I)

It is preferred that the curable component I contains at least onepolymer A1 having a curable group and a number average molecular weightof from 1,000 to 100,000, and at least one monomer A2 having a curablegroup and a molecular weight of from 125 to 600. When such a curablecomponent I is used, it is possible to easily adjust the viscosity ofthe resin composition to be within a preferred range, whereby it ispossible to easily produce the adhesive layer I.

The curable group in the polymer A1 or the monomer A2 may, for example,be an addition-polymerizable unsaturated group (such as an acryloyloxygroup or a methacryloyloxy group) or a combination of an unsaturatedgroup and a thiol group. From the viewpoint that the curing speed ishigh and that a highly transparent adhesive layer I is obtainable, thecurable group is preferably an acryloyloxy group or a methacryloyloxygroup.

The curable group in the polymer A1 and the curable group in the monomerA2 may be the same or different from each other.

In order to shorten the time required for the curing reaction, it ispreferred that the curable groups in the polymer A1 and the monomer A2are acryloyloxy groups with high reactivity.

(Polymer A1)

The number average molecular weight of the polymer A1 is preferably from1,000 to 100,000, more preferably from 10,000 to 70,000. When the numberaverage molecular weight of the polymer A1 is within this range, it iseasy to adjust the viscosity of the resin composition to be within theabove range. The number average molecular weight of the polymer A1 is anumber average molecular weight calculated as polystyrene, obtained bymeasurement of gel permeation chromatography (GPC). Here, in a casewhere a peak of an unreacted low molecular weight component (such as amonomer) appears in the measurement of GPC, the number average molecularweight is obtained by excluding such a peak.

The polymer A1 is preferably one having from 2 to 4 curable groups onaverage in one molecule, with a view to suppressing curability of theresin composition and the mechanical properties of the adhesive layer I.

The polymer A1 may, for example, be a urethane polymer having a urethanebond, a poly(meth)acrylate of a polyoxyalkylene polyol or apoly(meth)acrylate of a polyester polyol. A urethane polymer ispreferred with a view to widely adjusting e.g. the mechanical propertiesof the resin after curing or the adhesion to an object to be bonded, bymeans of e.g. molecular design of the urethane chain.

The urethane polymer may be synthesized by a method wherein a polyol anda polyisocyanate are reacted to obtain a prepolymer having an isocyanategroup, and then, a monomer is reacted to the isocyanate group of theprepolymer. The polyol and the polyisocyanate may be known compounds,for example, polyol i, diisocyanate ii, etc. disclosed as raw materialsfor a urethane polymer a disclosed in WO2009/016943, which areincorporated in this specification by reference.

The proportion of the polymer A1 in the curable component I ispreferably from 1 to 90 mass %, more preferably from 5 to 80 mass %.When the proportion of the polymer A1 is at least 1 mass %, the heatresistance of the adhesive layer I will be good. When the proportion ofthe polymer A1 is at most 90 mass %, the curability of the resincomposition and the adhesion between an object to be bonded and theadhesive layer I will be good.

(Monomer A2)

The molecular weight of the monomer A2 is preferably from 125 to 600.When the molecular weight of the monomer A2 is within this range, it ispossible to obtain the adhesive layer I having good adhesion. Themolecular weight of the monomer A2 is preferably from 140 to 400. Themonomer A2 is preferably one having from 1 to 3 curable groups in onemolecule, with a view to suppressing curability of the resin compositionand the mechanical properties of the adhesive layer I.

The proportion of the monomer A2 in the curable component I ispreferably from 10 to 99 mass %, more preferably from 20 to 95 mass %.

The monomer A2 can be roughly classified into a monomer A2′ having acurable group and a hydroxy group and a monomer A2″ having a curablegroup and no hydroxy group.

The monomer A2″ having a curable group and no hydroxy group ispreferably at least one member selected from an alkyl acrylate and analkyl methacrylate having a C₈₋₂₂ alkyl group. As a specific example ofthe monomer A2, n-decyl acrylate, n-dodecyl acrylate, n-dodecylmethacrylate, isooctadecyl acrylate, n-octadecyl methacrylate orn-behenyl methacrylate may be mentioned, and n-decyl acrylate, n-dodecylacrylate or n-dodecyl methacrylate is preferred.

In the present embodiment, the monomer A2 preferably contains themonomer A2′ having a curable group and a hydroxy group. When the monomerA2′ is contained in the curable component I, in a case where theafter-mentioned non-curable component I is contained in the resincomposition, it is possible to increase the compatibility of thenon-curable component II. Further, when the monomer A2′ is containedtherein, in a case where an object to be bonded is glass, the adhesionbetween the adhesive layer I and the glass improves, such beingpreferred.

The monomer A2′ may, for example, be 2-hydroxypropyl acrylate,2-hydroxybutyl acrylate, 4-hydroxybutyl acrylate, 6-hydroxyhexylacrylate, 2-hydroxypropyl methacrylate, 2-hydroxybutyl methacrylate,4-hydroxybutyl methacrylate or 6-hydroxyhexyl methacrylate. Among them,a hydroxy acrylate having a C₂₋₈ hydroxyalkyl group is preferred, and4-hydroxybutyl acrylate is particularly preferred.

Further, the proportion of the monomer A2′ in the curable component I ispreferably from 10 to 60 mass %, more preferably from 20 to 50 mass %.When the proportion of the monomer A2′ is at least 10 mass %, it ispossible to sufficiently obtain effects of improvement in stability ofthe resin composition and improvement in adhesion between the adhesivelayer I and an object to be bonded.

Further, the proportion of the monomer A2″ in the curable component I ispreferably from 10 to 60 mass %, more preferably from 20 to 50 mass %.When the proportion of the monomer A2′ is at least 10 mass %, thestability of the resin composition can be improved, and the shearmodulus G′ of the adhesive layer I can be readily within a range of from5×10² to 1×10⁵ Pa.

(Non-Curable Component II)

The non-curable component II is a component which undergoes no curingreaction with the curable compound I at the time of curing the curablecomponent I in the resin composition. In the present embodiment, thenon-curable component II is preferably a polymer B containing a hydroxygroup.

The number of hydroxy groups in one molecule of the polymer B ispreferably from 0.8 to 3, more preferably from 1.8 to 2.3. The numberaverage molecular weight of the polymer B is preferably from 400 to8,000, more preferably from 800 to 6,000.

When the number average molecular weight of the polymer B is from 400 to8,000, it is possible to increase the compatibility with the curablecomponent I in the resin composition. As a result, the adhesive layer Iobtainable by curing the resin composition can be transparent.

The polymer B may be used alone or in combination of two or more ofthem.

As an example of the polymer B, a high molecular weight polyol may bementioned, and a polyoxyalkylene polyol, a polyester polyol or apolycarbonate polyol is preferred. The polyoxyalkylene polyol may, forexample, be a polyoxyalkylene glycol such as polyoxyethylene glycol,polyoxypropylene glycol, polyoxypropylene glycol having a branchedstructure or polyoxytetramethylene glycol.

The polyoxyalkylene polyol may, for example, be an aliphatic polyesterdiol having a residue of an aliphatic diol such as ethylene glycol,propylene glycol or 1,4-butanediol, and a residue of an aliphaticdicarboxylic acid such as glutaric acid, adipic acid or sebacic acid.

The polycarbonate polyol may, for example, be an aliphatic polycarbonatediol having a diol residue of e.g. 1,6-hexanediol, or an aliphaticpolycarbonate diol such as a ring-opened polymer of an aliphatic cycliccarbonate.

As the polymer B, it is preferred to use a polyoxyalkylene polyol,particularly preferably polyoxypropylene polyol, with a view to loweringthe shear modulus G′ of the adhesive layer I after curing. Further, apart of oxypropylene groups in the polyoxypropylene polyol may besubstituted by an oxyethylene group. For example, from the viewpoint ofcompatibility, it is preferred that the polymer A1 is a urethane polymersynthesized by using a polyoxyalkylene polyol and a polyisocyanate asraw materials, and the polymer B is a polyoxyalkylene polyol.

When the non-curable component II is contained in the resin composition,it is possible to obtain an effect of shortening the time untildisappearance of air bubbles formed at the interface between theadhesive layer I and an object to be bonded under normal pressure. Theproportion of the non-curable component II in the resin composition ispreferably from 10 to 70 parts by mass based on the total mass (100parts by mass) of the curable component I. When the content of thenon-curable component II in the resin composition is within this range,it is possible to obtain a sufficient effect of disappearance of airbubbles, and further it is possible to sufficiently cure the adhesivelayer I. Further, in a case where at least two types of non-curablecomponents II are used, the proportion is a proportion of the totalamount of the non-curable components II.

(Photopolymerization Initiator III)

The photopolymerization initiator III contained in the resin compositionmay be a photopolymerization initiator of e.g. acetophenone type, ketaltype, benzoin or benzoin ether type, phosphine, oxide type, benzophenonetype, thioxanthene type or quinone type. A phosphine oxide type orthioxanthone type photopolymerization initiator is preferred, and with aview to preventing coloration after the photopolymerization reaction, aphosphine oxide type is particularly preferred. In a case where thephotopolymerization is carried out by high intensity light irradiation,it is preferred to use an acetophenone type photopolymerizationinitiator, whereby the curing speed may be increased. The content of thephotopolymerization initiator III in the resin composition is preferablyfrom 0.01 to 10 parts by mass, more preferably from 0.1 to 5 parts bymass, based on the total mass (100 parts by mass) of the curablecomponent I.

In addition to the curable component I, the non-curable component II andthe photopolymerization initiator III, the resin composition maycontain, as the case requires, various additives such as a chaintransfer agent, a polymerization inhibitor, a photocuring accelerator, aphotostabilizer (such as an ultraviolet absorber or a radicalscavenger), an antioxidant, a flame retardant, an adhesion-improvingagent (such as a silane coupling agent), a pigment, a dye, etc. Amongthem, a polymerization inhibitor, an antioxidant, etc. are preferablycontained. The total mass of such additives is preferably from 0 to 10parts by mass, more preferably from 0 to 5 parts by mass, based on thetotal mass (100 parts by mass) of the curable component I.

The chain transfer agent is a compound which receives radicals from apolymer grown by radical polymerization thereby to prevent elongation ofthe polymer. Therefore, by incorporating the chain transfer agent as anadditive to the resin composition and adjusting the content of the chaintransfer agent, it is possible to adjust the molecular weight of thecurable components after curing.

The chain transfer agent may, for example, be a compound having a thiolgroup, such as n-octylmercaptan, n-dodecylmercaptan,1,4-bis(3-mercaptobutylyloxy)butane or pentaerythritoltetrakis(3-mercaptobutylate).

The polymerization inhibitor is a compound which receives radicals froma polymer grown by radical polymerization thereby to terminate areaction. By incorporating the polymerization inhibitor as an additiveto the resin composition and adjusting its content to be lower than thepolymerization initiator, it is possible to improve the stability of theresin composition and adjust the molecular weight after curing.

The polymerization inhibitor may, for example, be2,5-di-tert-butylhydroquinone, mono-t-butylhydroquinone orp-t-butylcatechol.

When an antioxidant is incorporated as an additive for the resincomposition, it is possible to increase the stability of the resincomposition after curing. As a commercial antioxidant which can be addedto the resin composition, Irganox 1010, Irganox 1035, lrganox 1076 orIrgastab PUR68 manufactured by BASF SE, or ADK STAB, PEP-8 or PEP-36/36Amanufactured by ADEKA Corporation may, for example, be mentioned.

Now, one embodiment of the adhesive film of the present invention willbe described with reference to the drawings. One embodiment of anadhesive film having a single layer of the adhesive layer I is shown ineach of FIG. 1 and FIG. 2. FIG. 1 is a front view illustrating anembodiment of the adhesive film 10 having the adhesive layer 20sandwiched by protective films 30 and 31, and FIG. 2 is across-sectional view along I-I in FIG. 1.

The adhesive film of the present invention may be such that at least oneadhesive layer is the adhesive layer I, and may have at least twoadhesive layers. In the case of a structure having at least two adhesivelayers, it is possible to obtain e.g. an adhesive film having differentphysical properties such as adhesion between a front layer and a backlayer of the adhesive layer. FIG. 3 is a cross-sectional viewillustrating an embodiment having two adhesive layers, and illustratingan embodiment of the adhesive film 11 having the adhesive layers 21 and22 sandwiched by the protective films 30 and 31. In such a case, atleast one of the adhesive layers 21 and 22 may be the adhesive layer I,and both of them are preferably the adhesive layer I.

In a case where the adhesive film has at least two adhesive layers, theentire thickness of the adhesive layer may freely be set depending onthe application to bonding by using the adhesive film. For example, whena protective plate and a display panel of a display device are bondedusing the adhesive film, the entire thickness of the adhesive layer ispreferably from 0.15 to 2 mm, more preferably from 0.3 to 1.5 mm. Whenthe entire thickness of the adhesive layer is at least 0.15 mm, in acase where a protective plate and a display panel of a display deviceare bonded, the adhesive layer can effectively absorb e.g. a shock by anexternal force from the protective plate side, whereby it is possible toprotect the main body of the display device. Further, even if a foreignmatter not exceeding the entire thickness of the adhesive layer isincluded between the protective plate and the display panel of thedisplay device, the thickness of the adhesive layer is substantiallyunchanged, and influence over light transmitting performance is little.When the entire thickness of the adhesive layer is at most 2 mm, theprotective plate can easily be bonded to the display panel of thedisplay device via the adhesive layer, whereby it is possible todecrease the entire thickness of the display device.

(Protective Film)

The adhesive film of the present invention preferably has such anembodiment that the adhesive layer is in contact with a protective filmor that the adhesive layer is sandwiched by protective films, wherebye.g. processing, transporting and storing of the adhesive layer will beeasy.

The protective film preferably has a release agent on the surface to bein contact with the adhesive layer of a substrate. The release agentmay, for example, be a silicone resin. The protective films to be incontact with the front layer and the back layer of a laminate of theadhesive layers may be the same or different. In order that a desirablesurface layer side is peeled at the time of bonding the adhesive film,it is preferred to use different protective films so that there is adifference in the adhesion between the protective film and the adhesivelayer.

As a method for making a difference in adhesion, a method of employingdifferent thicknesses of the release layers for the protective films ora method of employing different release agents for the protective films,may be mentioned. Such a method may be freely designed depending on e.g.application of the adhesive film.

As the substrate for the protective film, a film of e.g. PET(polyethylene terephthalate), polyethylene, polypropylene or afluororesin may be used.

The thickness of the substrate for the protective film differs dependingupon a resin to be used, and it is preferably from 0.025 mm to 0.175 mm,more preferably from 0.038 mm to 0.125 mm when a PET film is used. Whena polyethylene film or a polypropylene film is used, it is preferablyfrom 0.04 mm to 0.2 mm, more preferably from 0.06 mm to 0.1 mm.

The protective film is preferably such that no gases such as oxygen gas,nitrogen gas and water vapor) permeate from outside. The gaspermeability of the protective film is preferably at most 100cc/m²·day·atm. For example, it is possible to reduce permeation of gasby providing a barrier layer of a film of an inorganic compound such asalumina on the substrate.

<Process for Producing Adhesive Film>

The process for producing the adhesive film in the present embodimentmay, for example, be a process for producing a single adhesive layer Iby using one type of a resin composition or a process for producing atleast two adhesive layers including at least one adhesive layer I byusing at least two types of resin compositions.

The adhesive layer may, for example, be produced by coating theprotective film with a resin composition, and irradiating it with lightto cure the resin composition. As an example of production of theadhesive film, a method for producing an adhesive film 10 having oneadhesive layer I by using a production apparatus 100 as shown in FIG. 4will be described.

As shown in FIG. 4, the production apparatus 100 comprises a first feedroll 50, a second feed roll 51, an application die 40, a bonding roll53, a curing part 60 and a first wind-up roll 52.

A protective film 30 is sequentially fed from the feed roll 50, and theprotective film 30 is continuously coated with a first resin compositionby the application die 40. Further, a protective film 31 is sequentiallyfed from the feed roll 51, and the protective film 31 is bonded to thefirst resin composition by the bonding roll 53.

Then, the first resin composition is cured by irradiating it with lightin the curing part 60 to form an adhesive layer (an adhesive layercorresponding to an adhesive layer 20 in FIG. 6), whereby a roll of theadhesive film 10 having the adhesive layer 20 sandwiched by theprotective film 30 and the protective film 31 is produced.

The curing part 60 has a chamber 61 and a light source 62 placed in thechamber 61. The number of the light sources is one in the case shown inFIG. 4, but the number of the light source may be at least two. Thelight source 42 is a light source capable of applying ultraviolet rays,and at least one light source selected from the group consisting of ahigh pressure mercury lamp, a metal halide lamp and LED may, forexample, be used. Further, the light source 62 may be positioned on theprotective film 30 side or the side coated with the resin composition.

The interior atmosphere of the, chamber 61 is not particularly limited.In a case where the interior of the chamber 61 is an inert gasatmosphere, at the time of irradiating the above-mentioned resincomposition with ultraviolet rays (light irradiation) for a curingreaction, it is possible to prevent a side reaction by oxygen todeactivate radicals formed in the resin composition by irradiation withultraviolet rays, such being preferred. The inert gas atmosphere ispreferably such that the oxygen concentration would be at most 100 ppm,for example, by filling the interior of the chamber 41 with nitrogen.

As another example of production of the adhesive film, a process forproducing an adhesive film 11 having two adhesive layers by using aproduction apparatus 110 as shown in FIG. 5, will be explained.

As shown in FIG. 5, the production apparatus 110 comprises the firstfeed roll 50, the second feed roll 51, the first application die 40, thefirst curing part 60, a second application die 41, a second curing part63 and the first wind-up roll 52.

The protective film 30 is sequentially fed from the feed roll 50, andthe protective film 30 is continuously coated with the first resincomposition into a stripe shape by the first application die 40. Then,the first resin composition is cured by irradiating it with light in thefirst curing part 60 to form an adhesive layer (an adhesive layercorresponding to an adhesive layer 21 in FIG. 7).

Then, the adhesive layer 21 is continuously coated with the second resincomposition into a stripe shape by the second application die 41.Further, the protective film 31 is sequentially fed from the feedingroll 51, and the protective film 31 is bonded to the second resincomposition by the bonding roll 53.

Then, the second resin composition is cured by irradiating it with lightin the second curing part 63 to form an adhesive layer (an adhesivelayer corresponding to the adhesive layer 22 in FIG. 7), whereby a rollof the adhesive film 11 having a laminate (the adhesive layer 20) of theadhesive layer 21 and the adhesive layer 22 sandwiched by the protectivefilm 30 and the protective film 31 is produced.

In the production apparatus 110, the first resin composition and thesecond resin composition to be used may be the same composition ordifferent compositions. When the first and the second resin compositionsare the same composition, it is possible to produce an adhesive filmhaving a thick adhesive layer, and when the first and the second resincompositions to be used are different compositions, it is possible toproduce an adhesive film having different physical properties betweenthe front layer and the back layer.

Further, the application thicknesses of the resin compositions appliedby the first application die and the second application die may be thesame or different. Such an application thickness may be suitablyadjusted depending upon the design of the adhesive film to be produced.

The atmosphere and the light irradiation conditions in each of the firstcuring part 60 and the second curing part 63 are the same as in thecuring part of the production apparatus 100. The atmosphere and thelight irradiation conditions in the first curing part 60 and the secondcuring part 63 may be the same or different. Further, the light sources62 and 65 may be positioned on the protective film 30 side or the sidecoated with the resin composition.

As another example of production of the adhesive film, a process may bementioned, wherein at least two adhesive films 10 produced by theproduction apparatus 100 as shown in FIG. 4 are prepared, protectivefilms on one side of the respective adhesive films 10 are peeled, andthe adhesive films 10 are laminated. When the resin compositions of theadhesive layers in the adhesive films to be used have the samecomposition, the adhesive layer can be thick with the same physicalproperties, and when the resin compositions have a differentcomposition, an adhesive film having different physical propertiesbetween the front layer and the back layer can be produced.

The adhesive film is used by cutting it into a desired size depending onthe application. The adhesive film may be cut by a laser cutter or arotary blade. In a case where the adhesive film is soft and has a shearmodulus being smaller than 100 kPa, it is preferred to use a lasercutter with a view to preventing re-attachment after cutting.

<Adhesive Layer-Equipped Transparent Plate>

As shown in FIG. 6 or FIG. 7, an adhesive layer-equipped transparentplate 80 of the present embodiment has at least one adhesive layer 20 ona transparent plate 81. FIG. 6 and FIG. 7 illustrate embodiments of anadhesive layer-equipped transparent plate using the transparent plate 81as a protective plate for a display device as explained below, whichcomprises the transparent plate 81 having a light-shielding printedportion 82 at the peripheral portion and at least one adhesive layer 20thereon, and the protective film 31 on the surface of the adhesive layer20 opposite from the transparent plate 81.

The adhesive layer-equipped transparent plate of the present embodimenthas at least one adhesive layer I. In a case where at least two adhesivelayers are provided thereon, at least one layer should be the adhesivelayer I, and it is preferred that all of them are the adhesive layer I.Further, the respective adhesive layers may be the same or different

[Transparent Plate]

The transparent plate has transparency, and the plan view shape or thecross-sectional shape thereof is not limited. The plan view shape isdesigned depending on the application to be used, such as rectangular,or a linear or curve at the periphery. The cross-sectional shape may bea linear shape (that is a rectangular cross-sectional shape), a bentshape, or a combination of a linear shape and a bent shape having alinear shape at the center portion and a bent shape at the end portion.

The material for the transparent plate may be glass or a transparentresin. A glass material may, for example, be soda lime glass oraluminosilicate glass. As the glass, a high transparent glass ortempered glass may be used, and especially in a case where a thintransparent plate is used, chemically tempered glass is preferred. As atransparent resin material, a resin material having high transparency(such as an acrylic resin such as polycarbonate or polymethylmethacrylate) may be mentioned.

The thickness of the transparent plate is usually preferably from 0.5 to25 mm in the case of a glass plate, and is preferably from 2 to 10 mm inthe case of a transparent resin plate, from the viewpoint oftransparency.

In order to improve the interfacial adhesive force with the adhesivelayer, surface treatment may be applied to the transparent plate. Themethod for the surface treatment may, for example, be a method oftreating the surface of the transparent plate with a silane couplingagent, or a method of forming a thin film of silicon oxide by oxidativeflame by a flame burner.

[Protective Plate for Display Device]

The above transparent plate can be suitably used as a protective plateto be used for protecting a display panel of a display device. In a casewhere the transparent plate is used as a protective plate, the materialfor the protective plate is preferably a glass plate from the viewpointof light resistance, low birefringence, high flatness, surfacescratching resistance and high mechanical strength, as well as thetransparency to emitted light or reflected light from the display panel.

In a case where the transparent plate is used as a protective plate, inorder to increase the contrast of a display image, an anti-reflectionlayer may be provided on the opposite side of the protective plate fromthe surface on which the adhesive layer is formed. The anti-reflectionlayer may be provided by a method of directly forming an inorganic thinfilm having a low refractive index on the surface of the protectiveplate, or a method of bonding a transparent resin film provided with theanti-reflection layer to the protective plate.

The protective plate may be partly or entirely colored; part or whole ofthe surface of the protective plate may be made to be ground-glass toscatter light; or e.g. fine irregularities may be formed on part orwhole of the surface of the protective plate to refract or reflecttransmitted light. Or, a colored film, a light-scattering film, alight-refracting film, a light-reflecting film, etc. may be bonded topart or whole of the surface of the protective plate.

In a case where a transparent plate is used as a protective plate, inapplications to e.g. TV receivers, PC displays, etc., the thickness ispreferably from 0.5 mm to 6 mm with a view to weight reduction of thedisplay device, and in applications to public displays to be installedoutdoor, the thickness is preferably from 3 mm to 20 mm. In the case ofusing chemically tempered glass, the thickness of the protective plateis preferably from about 0.4 mm to 1.5 mm.

[Light-Shielding Printed Portion]

It is preferred that the protective plate is provided with a lightshielding portion along the periphery of the protective plate (thetransparent plate), that is the light-shielding printed portion 82 isprovided along the periphery of the transparent plate 81, as shown inFIG. 6 and FIG. 7, so that the region other than the image displayregion of the display panel would be invisible from the protective plateside, whereby it is possible to shield e.g. wiring members connected tothe display panel. The light-shielding portion is preferably formed onthe surface where the adhesive layer is formed of the protective plate.

A method for forming the light-shielding portion may, for example, be amethod of printing a ceramic coating material containing a black pigmentor a method of bonding a transparent film preliminarily provided with alight-shielding portion.

<Method for Producing Adhesive Layer-Equipped Transparent Plate>

A method for producing the adhesive layer-equipped transparent plate ofthe present embodiment may, for example, be a method wherein an adhesivefilm is transferred onto a transparent plate or a method wherein a resincomposition is directly applied on a transparent plate and cured to forman adhesive layer.

Regarding the method wherein an adhesive film is transferred onto atransparent plate, in a case where a plurality of adhesive layers areprovided on the transparent plate, a method of cutting the adhesive filmof the present embodiment into a desired size and then transferring atleast one of them onto the transparent plate, or a method ofpreliminarily bonding the adhesive films of the present embodiment toeach other and then cutting them into a desired shape and transferringthem onto the transparent plate, may, for example, be mentioned.

As the method wherein a resin composition is directly applied on atransparent plate to form an adhesive layer, a die coating method or amethod using a dispenser may, for example, be mentioned. After the resincomposition is applied on the transparent plate, a protective film isbonded to the resin composition, and ultraviolet rays are appliedthereto for curing, whereby an adhesive layer is formed. The method andconditions for applying ultraviolet rays are preferably the same as theultraviolet ray irradiation in the process for producing the adhesivefilm of the present embodiment.

<Laminate>

The adhesive film of the present invention is suitably used for bondingplates to each other to produce a laminate. For example, the adhesivefilm is used for bonding a pair of glass plates to produce a laminatedglass. Further, the adhesive film is used to bond a protective plate anda display panel to produce a display device.

Further, the adhesive layer-equipped transparent plate of the presentinvention may, for example, be bonded to a display panel to produce adisplay device.

Now, a display device will be explained as an example in which theadhesive film and the adhesive layer-equipped transparent plate areused.

FIG. 8 is a cross-sectional view illustrating one example of theembodiment of a display device.

A display device 1000 of the present embodiment comprises a displaypanel 90 and the protective plate 81 (that is, a transparent plate)bonded via the adhesive layer 20. As the adhesive layer 20 of thepresent embodiment, the adhesive layer I is used.

The display panel 90 is a liquid crystal panel having such a structurethat a transparent substrate 92 having a color filter, and a transparentsubstrate 94 having TFT (thin film transistor) are bonded via a liquidcrystal layer 96, and such an assembly is sandwiched by a pair ofpolarizing plates 98.

A method for producing the display device 1000 may, for example, be amethod of preparing an adhesive film of the present embodiment havingprotective films on both sides, peeling one protective film and bondingthe adhesive film to a transparent plate as the protective plate 81, andpeeling the other protective film and bonding the adhesive film to thedisplay surface of the display panel, or a method of preparing anadhesive layer-equipped transparent plate of the present embodiment,peeling a protective film and bonding the plate to the display surfaceof the display panel.

EXAMPLES

Now, the embodiment of the present invention will be described withreference to Examples and Comparative Examples. Ex. 1 to 5 are Examplesof the present invention, and Ex. 6 and 7 are Comparative Examples.

Ex. 1

A resin composition to form an adhesive layer was produced as follows.

Bifunctional polypropylene glycol having molecular terminals modifiedwith ethylene oxide (number average molecular weight calculated byhydroxy value: 4,000) and isophorone diisocyanate were mixed in a molarratio of 4:5 and reacted at 70° C. in the presence of a tin catalyst toobtain a prepolymer. This prepolymer and 2-hydroxyethyl acrylate weremixed in a molar ratio of approximately 1:2 and reacted at 70° C. toobtain an urethane acrylate polymer (hereinafter abbreviated as UA). UAhad two curable groups, a number average molecular weight of about24,000 and a viscosity of about 830 Pa·s at 25° C.

The above UA as the polymer A1, 4-hydroxybutyl acrylate (product name:4HBA, manufactured by Osaka Organic Chemical Industry Ltd.) as themonomer A2′ and n-dodecyl acrylate (product name: light acrylate L-A LA,manufactured by Kyoeisha Chemical Co., Ltd.,) as the monomer A2′ wereprepared. These components were mixed in a proportion by parts by massas shown in Table 1 to obtain a curable component I.

Then, bis(2,4,6)-trimethylbenzoyl)-phenylphosphine oxide (product name:IRGACURE 819, manufactured by BASF) as the photopolymerization initiatorIII (represented as polymerization initiator III in Table 1),n-dodecylmercaptan (product name: THIOKALCOL 20, manufactured by KaoCorporation) as a chain transfer agent, pentaerythritoltetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] (product name:IRGANOX 1010 manufactured by BASF) as an antioxidant,2,5-di-tert-butylhydroquinone (DTBHQ manufactured by Tokyo ChemicalIndustry Co., Ltd.,) as a polymerization inhibitor and an ultravioletabsorber (Tinuvin 383-2 manufactured by BASF) were prepared. Thesecomponents were mixed with the curable component I in a proportion byparts by mass as shown in Table 1, based on 100 parts by mass of thecurable component I.

Then, as the non-curable component II, bifunctional polypropylene glycolhaving molecular terminals modified with ethylene oxide (number averagemolecular weight: 4,000) and bifunctional polypropylene glycol havingmolecular terminals modified with ethylene oxide (number averagemolecular weight: 7,000) were prepared. They were added to the abovemixture in a proportion by parts by mass as shown in Table 1, based on100 parts by mass of the curable component I, followed by mixing toobtain a resin composition1.

A silicone sheet (thickness: 0.5 mm) having its center portion hollowedout, was placed on a mold release PET film (150 mm×150 mm, thickness:125 μm) as a protective film, and the resin composition 1 was applied onits center portion by means of bar coating. A mold release PET film (150mm×150 mm, thickness: 75 μm) was laminated on the resin composition 1.The laminate was irradiated with ultraviolet rays with a mercury lamp(cumulative radiation: 1,500 mJ/cm²) to cure the resin composition 1 toobtain an adhesive film 1 having one adhesive layer.

The thickness of the adhesive layer was 0.5 mm.

Ex. 2

A resin composition 2 was obtained in the same manner as in Ex. 1 exceptthat the proportion by parts by mass of each component in the resincomposition was changed as shown in Table 1. Using the resin composition2, an adhesive film 2 having one adhesive layer was obtained in the samemanner as in Ex. 1.

Ex. 3

A resin composition 3 was obtained in the same manner as, in Ex. 1except that the polymerization initiator III was changed to1-hydroxycyclohexyl phenyl ketone (product name: IRGACURE 184,manufactured by BASF), the antioxidant was changed to IRGASTAB PUR68(product name) manufactured by BASF, no ultraviolet absorber and nonon-curable component II were used, and the proportion by parts by massof each component was changed as shown in Table 1. Using the resincomposition 3, an adhesive film 3 having one adhesive layer was obtainedin the same manner as in Ex. 1.

Ex. 4

A resin composition 4 was obtained in the same manner as in Ex. 3 exceptthat the non-curable component II was used and the proportion by partsby mass was changed as shown in Table 1. Using the resin composition 4,an adhesive film 4 having one adhesive layer was obtained in the samemanner as in Ex. 1.

Ex. 5

A resin composition 5 was obtained in the same manner as in Ex. 3 exceptthat the proportion by parts by mass was changed as shown in Table 1.Using the resin composition 5, an adhesive film 5 having one adhesivelayer was obtained in the same manner as in Ex. 1.

Ex. 6

Three sheets of commercially available high transparency adhesive films(product name: CEF03A07, manufactured by 3M) each having a thickness of0.175 mm, were laminated to obtain an adhesive film 6 having threeadhesive layers.

Ex. 7

Three sheets of commercially available high transparency adhesive films(product name: CEF0507, manufactured by 3M) each having a thickness of0.175 mm were laminated to obtain an adhesive film 7 having threeadhesive layers.

The adhesive films 1 to 7 obtained in Ex. 1 to 7 were used to carry outthe following evaluation. The results are shown in Table 2.

(Gas Diffusion Coefficient Measurement)

Permeability coefficient measurements of nitrogen gas, oxygen gas andair were carried out by using a high temperature and high pressure, gaspermeability measurement apparatus (product name: K-315-H, manufacturedby Tsukuba Rika Seiki K.K.) by the following method.

A measurement sample was prepared in such a manner that one mold releasePET of the adhesive film was peeled, the adhesive film was bonded to anoriented polypropylene (OPP) substrate having a thickness of 30 μm, thenthe other mold release PET was peeled, and the adhesive film wassandwiched by a cell having a diameter of 50 mm.

In the measurement, high purity nitrogen gas and oxygen gas, and airwere respectively used.

Nitrogen gas, oxygen gas or air was introduced from the OPP substrateside at 25° C. and 100 kPa, and changes with time of pressure ofnitrogen gas, oxygen gas and air permeated through the sample sandwichedby the cell were measured by a mass spectrometer to obtain permeabilitycurves.

The diffusion coefficient D of each of nitrogen, oxygen and air wascalculated by the formula 2 from the delay time t₀ in a non-steady statein the permeability curve obtained. Further, the value (t₀=t₁−t₂)obtained by subtracting a delay time t₂ in a non-steady state in apermeability curve of a sample which is only the OPP substrate, from adelay time t₁ in a non-steady state in a permeability curve of a samplewhich is an adhesive layer provided with a substrate, was regarded asthe delay time t₀.

D=L ²/(6×t ₀)   Formula 2

wherein L is a film thickness (unit: cm) of the adhesive layer.

Further, in Table 2, each diffusion coefficient (cm²/sec.) wasrepresented by a unit of “cm²/sec”.

(Shear Modulus Measurement and Loss Tangent Measurement)

Using ARES-G2 rheometer (product name) manufactured by TA Instruments, ashear modulus and loss tangent (tan δ) of the adhesive layer weremeasured as follows. At 25° C., frequency of 0.01 to 100 Hz anddistortion of 3%, a parallel plate of 25 mm was used. The shear modulusand loss tangent (tan δ) at a frequency of 1 Hz were regarded as a shearmodulus and loss tangent (tan δ) at 25° C. The values of the shearmodulus and loss tangent (tan δ) were not influenced by the thickness ofthe adhesive film and therefore one sheet (thickness: 0.175 μm) of acommercially available high transparency adhesive film was used withoutlamination, in Ex. 6 and Ex. 7.

(Glass Transition Temperature Measurement)

A glass transition temperature of the adhesive layer of each of theadhesive films 1 to 7 was measured by means of DVA-200 (product name)manufactured by ITK Co., Ltd. The measurement was carried out at ameasurement temperature of from −120 to 180° C., a temperature-raisingrate of 3° C./min. and a frequency of 1 Hz, and in the chart of atemperature change of a tensile dynamic modulus E′, the intersectingpoint at which a low-temperature side tangent line of the tensiledynamic modulus E′ intersects with a tangent line of a region where thetensile dynamic modulus E′ rapidly decreases, was regarded as the glasstransition temperature of the adhesive layer.

(Bubble Disappearance Evaluation)

A glass plate (dimension: 55 mm×120 mm×0.7 mm, opening portion: 49 mm×90mm) having a light-shielding printed portion with a height of 80 μm at aperipheral portion was prepared. One mold release PET in each of theadhesive films 1 to 7 was peeled and the adhesive film was bonded to theglass plate, to obtain adhesive layer equipped glass plates 1 to 7. Fromeach of the adhesive layer equipped glass plates 1 to 7, the other moldrelease PET was peeled and the glass plate was bonded to the surface ofa polarizing plate of a 0.2 mm-thickness polarizing plate-equipped glass(53 mm×96 mm, thickness: 0.7 mm) via the adhesive layer at a torque of0.4 N·m thereby to obtain an evaluation sample. A time until bubblesformed on the interface between the adhesive layer and the polarizingplate disappeared was measured, and the time was represented as thebubble disappearance property. The time until the bubbles disappearedwas 168 hours at a maximum.

TABLE 1 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Curable Polymer A1 50 50 50 50 50component I Monomer A2′ 20 10 20 20 20 Monomer A2″ 30 40 30 30 30Non-curable Polypropylene glycol 20 20 0 20 0 component II (numberaverage molecular weight: 4,000) Polypropylene glycol 20 20 0 20 0(number average molecular weight: 7,000) Polymerization Bis(2,4,6)- 0.50.5 Initiator III trimethylbenzoyl- phenylphosphine oxide1-hydroxycyclohexyl 3 3 3 phenyl ketone Chain transfer THIOKALCOL 20 0.50.2 1 0.5 0.5 agent Polymerization DtBHQ 0.08 0.08 0.08 0.08 0.08inhibitor Antioxidant Pentaerythritol tetrakis[3- 0.5 0.5(3,5-di-tert-butyl-4- hydroxyphenyl)propionate] IRGASTAB PUR68 (product1 1 1 name) Ultraviolet TINUVIN 383-2 (product 0.3 0.1 0 0 0 absorbername)

TABLE 2 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 7 Nitrogen diffusion 2.1× 10⁻⁶ 1.9 × 10⁻⁶ 1.6 × 10⁻⁶ 1.7 × 10⁻⁶ 2.0 × 10⁻⁶ 1.1 × 10⁻⁶ 0.4 × 10⁻⁶coefficient (cm²/sec.) Oxygen diffusion 2.6 × 10⁻⁶ 2.6 × 10⁻⁶ 2.1 × 10⁻⁶2.3 × 10⁻⁶ 2.3 × 10⁻⁶ 1.9 × 10⁻⁶ 0.7 × 10⁻⁶ coefficient (cm²/sec.) Airdiffusion 2.0 × 10⁻⁶ 2.1 × 10⁻⁶ 1.9 × 10⁻⁶ 1.8 × 10⁻⁶ 2.0 × 10⁻⁶ 1.6 ×10⁻⁶ 0.8 × 10⁻⁶ coefficient (cm²/sec.) Shear modulus (Pa) 9.6 × 10³  14× 10³  40 × 10³  11 × 10³  38 × 10³  30 × 10³  86 × 10³  Loss tangent   0.53    0.36    0.46    0.49    0.44 — — Glass transition −72  −72 −68 −73 −70  −60 −31 temperature (° C.) Bubble disappearance 15 97 168 6 43 Not Not time (hour) disappeared disappeared

The adhesive layer of the adhesive film in Ex. 1 to 7, had an absorptionpeak at from 800 to 820 cm⁻¹ and no absorption peak at from 1,000 to1,020 cm⁻¹, in an infrared absorption spectrum, which is not shown inTables.

In the adhesive films in Ex. 1 to 5, the diffusion coefficient ofnitrogen gas and the shear modulus G′ (1 Hz) of the adhesive layer werewithin prescribed ranges, the diffusion coefficient of the nitrogen gaswas thus high, and therefore bubbles formed at the interface between theadhesive layer and the polarizing plate disappeared in a short period oftime. On the other hand, in Ex. 6 where a conventional adhesive film wasused, the shear modulus G′ (1 Hz) of the adhesive layer was within aprescribed range, but the diffusion coefficient of nitrogen gas of theadhesive layer was low, and therefore bubbles formed at the interfacebetween the adhesive layer and the polarizing plate did not disappear atthe expiration of 168 hours. Further, in Ex. 7, the diffusioncoefficient of nitrogen gas of the adhesive layer was low, further theshear modulus G′ (1 Hz) of the adhesive layer was also high, andtherefore bubbles formed at the interface between the adhesive layer andthe polarizing plate did not disappear at the expiration of 168 hours.

INDUSTRIAL APPLICABILITY

According to the present invention, it is possible to provide anadhesive film by which, even if air bubbles are formed at the bondinginterface when the adhesive film is used for bonding plates, the airbubbles disappear under normal pressure, and to provide an adhesivelayer-equipped transparent plate. Further, it is possible to provide adisplay device in which formation of air bubbles is suppressed.

This application is a continuation of PCT Application No.PCT/JP2016/053566, filed on Feb. 5, 2016, which is based upon and claimsthe benefit of priority from Japanese Patent Application No. 2015-033448filed on Feb. 24, 2015. The contents of those applications areincorporated herein by reference in their entireties.

REFERENCE SYMBOLS

10, 11: Adhesive film, 20, 21, 22: Adhesive layer, 30, 31, 32, 33:Protective film, 40, 41: Application die, 50, 51: Feed roll, 52: Wind-uproll, 53: Bonding roll, 60, 63: Application portion, 61, 64: Chamber,62, 65: Light source, 80: Adhesive layer-equipped transparent plate, 81:Transparent plate, 82: Light-shielding portion.

1. An adhesive film comprising at least one adhesive layer formed bycuring a resin composition containing at least one polymer A1 having acurable group and a number average molecular weight of from 1,000 to100,000, wherein the adhesive layer satisfies the following requirements(a) to (c): (a) a diffusion coefficient of nitrogen gas is at least1.5×10⁻⁶ cm²/sec, (b) a shear modulus G′ (1 Hz) is from 5×10² to 1.0×10⁵Pa, at a measurement temperature of 25° C. and a frequency of 1 Hz, and(c) the adhesive layer has an absorption peak at from 800 to 820 cm⁻¹and no absorption peak at from 1,000 to 1,020 cm⁻¹, in an infraredabsorption spectrum.
 2. The adhesive film according to claim 1, whereinthe adhesive layer has a glass transition temperature of at most −65° C.3. The adhesive film according to claim 1, wherein the adhesive layerhas a tan δ of from 0.01 to 1.4 at a measurement temperature of 25° C.and a frequency of 1 Hz.
 4. The adhesive film according to claim 1,wherein the resin composition further contains a non-curable component.5. The adhesive film according to claim 4, wherein the non-curablecomponent contains a hydroxy group.
 6. The adhesive film according toclaim 1, wherein the diffusion coefficient of nitrogen gas in theadhesive layer is at most 3.0×10⁻⁶ cm²/sec.
 7. An adhesivelayer-equipped transparent plate comprising a transparent plate and atleast one adhesive layer formed by curing a resin composition containingat least one polymer A1 having a curable group and a number averagemolecular weight of from 1,000 to 100,000, wherein the adhesive layersatisfies the following requirements (a) to (c): (a) a diffusioncoefficient of nitrogen gas is at least 1.5×10⁻⁶ cm²/sec, (b) a shearmodulus G′ (1 Hz) is from 5×10² to 1.0×10⁵ Pa, at a measurementtemperature of 25° C. and a frequency of 1 Hz, and (c) the adhesivelayer has an absorption peak at from 800 to 820 cm⁻¹ and no absorptionpeak at from 1,000 to 1,020 cm⁻¹, in an infrared absorption spectrum. 8.The adhesive layer-equipped transparent plate according to claim 7,wherein the adhesive layer has a glass transition temperature of at most−65° C.
 9. The adhesive layer-equipped transparent plate according toclaim 7, wherein the adhesive layer has a tan δ of from 0.1 to 1.4, at ameasurement temperature of 25° C. and a frequency of 1 Hz.
 10. Theadhesive layer-equipped transparent plate according to Clair 7, whereinthe resin composition further contains a non-curable component.
 11. Theadhesive layer-equipped transparent plate according to claim 10, whereinthe non-curable component contains a hydroxy group.
 12. The adhesivelayer-equipped transparent plate according to claim 7, wherein thediffusion coefficient of nitrogen gas in the adhesive layer is at most3.0×10⁻⁶ cm²/sec.
 13. The adhesive layer-equipped transparent plateaccording to claim 7, wherein the transparent plate is a protectiveplate for a display device.
 14. A display device having a transparentplate and a display panel laminated via the adhesive film as defined inclaim 1.